Hinged composite sandwich panels

ABSTRACT

An apparatus comprises a composite sandwich panel, a seal, and a hinge. The composite sandwich panel has a first edge in a first over-crush edge region, wherein a thickness of the composite sandwich panel decreases within the first over-crush edge region in a direction towards the first edge. The seal is bonded to the first over-crush edge region of the composite sandwich panel and extending past the first edge. The hinge is connected to the composite sandwich panel such that an axis of rotation of the hinge is positioned over the first over-crush edge region of the composite sandwich panel.

CROSS-REFERENCE TO RELATED CASE

This application is a divisional application of application Ser. No.15/887,898 filed with the U.S. Patent and Trademark Office on Feb. 2,2018, and issued a Notice of Allowance therefrom on May 14, 2020. Allmaterial in parent application Ser. No. 15/887,898 is incorporatedherein in its entirety.

BACKGROUND INFORMATION 1. Field

The present disclosure relates generally to cabinetry doors and, morespecifically, to forming cabinetry doors using composite sandwichpanels.

2. Background

Today, cabinetry inside aircraft lavatories is typically formed ofeither injection-molded or thermoformed plastics. These injection-moldedor thermoformed plastics are usually painted in solid colors. Cabinetryinside aircraft lavatories is visible and accessible to passengerswithin the aircraft.

Cabinetry in aircraft lavatories is desirably accessed only by aircraftpersonnel. Cabinetry in aircraft lavatories desirably containsconsistent, tight gaps between cabinetry panels. Consistent, tight gapsbetween cabinetry panels create a desirable decorative appearance.Consistent, tight gaps between cabinetry panels may reduce visibility ofdoors in cabinetry to passengers.

Commercial aircraft are in service for decades. During the course of anaircraft's lifetime, components are replaced during maintenance due towear or replacement schedules.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. It would be desirable to have an improvedability to customize the decorative face of aircraft lavatory cabinets.It would also be desirable to reduce frequency of replacement ofcomponents of aircraft lavatory cabinetry.

SUMMARY

An illustrative embodiment of the present disclosure provides anapparatus. The apparatus comprises a composite sandwich panel, a seal,and a hinge. The composite sandwich panel has a first edge in a firstover-crush edge region, wherein a thickness of the composite sandwichpanel decreases within the first over-crush edge region in a directiontowards the first edge. The seal is bonded to the first over-crush edgeregion of the composite sandwich panel and extending past the firstedge. The hinge is connected to the composite sandwich panel such thatan axis of rotation of the hinge is positioned over the first over-crushedge region of the composite sandwich panel.

Another illustrative embodiment of the present disclosure provides amethod. A seal is bonded to a first over-crush edge region of acomposite sandwich panel, wherein a thickness of the composite sandwichpanel decreases within the first over-crush edge region in a directiontowards a first edge of the composite sandwich panel within the firstover-crush edge region. A hinge is connected to the first over-crushedge region of the composite sandwich panel.

Yet another illustrative embodiment of the present disclosure providesan apparatus. The apparatus comprises a composite sandwich panel, apanel, and a hinge. The composite sandwich panel has a cut first edge, acut second edge, and a cut third edge each with a flat appearancewithout visible core cells. The seal is bonded to the composite sandwichpanel adjacent the cut first edge. The hinge is connected to thecomposite sandwich panel adjacent the cut first edge.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a block diagram of a manufacturingenvironment in which composite sandwich panels are used to form a doorin accordance with an illustrative embodiment;

FIG. 2 is an illustration of a front view of a lavatory cabinetry with adoor formed of a composite sandwich panel in accordance with anillustrative embodiment;

FIG. 3 is an illustration of a back view of a lavatory cabinetry with adoor formed of a composite sandwich panel in accordance with anillustrative embodiment;

FIG. 4 is an illustration of a front isometric view of a compositesandwich panel in accordance with an illustrative embodiment;

FIG. 5 is an illustration of a back isometric view of a compositesandwich panel in accordance with an illustrative embodiment;

FIG. 6 is an illustration of a front isometric view of a compositesandwich panel with a seal in accordance with an illustrativeembodiment;

FIG. 7 is an illustration of a front isometric view of a compositesandwich panel with a seal and a hinge in accordance with anillustrative embodiment;

FIG. 8 is an illustration of a side view of a composite sandwich panelin accordance with an illustrative embodiment;

FIG. 9 is an illustration of a side view of a composite sandwich panelwith a seal in accordance with an illustrative embodiment;

FIG. 10 is an illustration of a side view of a composite sandwich panelwith a seal and a hinge in accordance with an illustrative embodiment;

FIG. 11 is another illustration of a side view of a composite sandwichpanel with a seal and a hinge in accordance with an illustrativeembodiment;

FIG. 12 is an illustration of a side view of a composite sandwich panelwith a seal and a hinge installed in cabinetry and in a closed positionin accordance with an illustrative embodiment;

FIG. 13 is an illustration of a side view of a composite sandwich panelwith a seal and a hinge installed in cabinetry and in an open positionin accordance with an illustrative embodiment;

FIG. 14 is an illustration of a flowchart of a method for forming andusing a composite sandwich panel in accordance with an illustrativeembodiment;

FIG. 15 is an illustration of an aircraft manufacturing and servicemethod in the form of a block diagram in accordance with an illustrativeembodiment; and

FIG. 16 is an illustration of an aircraft in the form of a block diagramin which an illustrative embodiment may be implemented.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. For example, the illustrative embodimentsrecognize and take into account that it is desirable to create cabinetrydoors with greater durability to decrease replacement frequency. Theillustrative embodiments recognize and take into account that it isdesirable to increase the strength of the doors of aircraft lavatorycabinetry. The illustrative embodiments recognize and take into accountthat it is desirable to decrease the weight of aircraft components. Theillustrative embodiments recognize and take into account that it isdesirable to maintain straight, tight gaps between door panels inlavatory cabinetry. The illustrative embodiments recognize and take intoaccount that it is desirable to prevent sagging doors in order tomaintain straight, tight gaps between door panels in lavatory cabinetry.

The illustrative embodiments recognize and take into account thatcomposite sandwich panels have a high strength to weight ratio. Theillustrative embodiments recognize and take into account that to formcomposite sandwich panels, composite skins are compressed against ahollow cell core. The illustrative embodiments recognize and take intoaccount that conventionally, it is desirable to prevent over-crush ofthe hollow cell core.

The illustrative embodiments recognize and take into account that cutedges of composite sandwich panels have visible core cells. Theillustrative embodiments recognize and take into account that edge trimmay be applied to cut edges of composite sandwich panels to cover thevisible core cells. The illustrative embodiments recognize and take intoaccount that the edge trim is not considered desirably decorative ordesirably durable by aircraft customers. The illustrative embodimentsrecognize and take into account that the edge trim may cause doors inlavatory cabinetry to be undesirably visible to passengers. Theillustrative embodiments recognize and take into account that thepresence of edge trims may call a passenger's attention to the fact thatthere is a door present. The illustrative embodiments recognize and takeinto account that it is desirable for doors to remain effectivelydisguised from passengers.

The illustrative embodiments recognize and take into account that thethickness of an edge of a composite sandwich panel affects the size ofgaps in lavatory cabinetry. The illustrative embodiments recognize andtake into account that increasing the thickness of an edge of acomposite sandwich panel increases the size of the gaps in the lavatorycabinetry.

The illustrative examples present an apparatus and method for forming adoor comprising a composite sandwich panel. One illustrative embodimentpresents an apparatus comprising a composite sandwich panel, a seal, anda hinge. The composite sandwich panel has a first edge in a firstover-crush edge region, wherein a thickness of the composite sandwichpanel decreases within the first over-crush edge region in a directiontowards the first edge. The seal is bonded to the first over-crush edgeregion of the composite sandwich panel and extending past the firstedge. The hinge is connected to the composite sandwich panel such thatan axis of rotation of the hinge is positioned over the first over-crushedge region of the composite sandwich panel.

Referring now to the figures and, in particular, with reference to FIG.1 , an illustration of a block diagram of a manufacturing environment inwhich composite sandwich panels are used to form a door is depicted inaccordance with an illustrative embodiment. Composite sandwich panel 100in manufacturing environment 102 has first edge 104 in first over-crushedge region 106. Thickness 108 of composite sandwich panel 100 decreaseswithin first over-crush edge region 106 in a direction towards firstedge 104.

Seal 110 is bonded to first over-crush edge region 106 of compositesandwich panel 100. Seal 110 extends past first edge 104.

Hinge 112 is connected to composite sandwich panel 100 such that axis ofrotation 114 of hinge 112 is positioned over first over-crush edgeregion 106 of composite sandwich panel 100.

In some illustrative examples, seal 110 ends before reaching hinge 112.In some illustrative examples, a portion of seal 110 is sandwichedbetween hinge 112 and composite sandwich panel 100.

In some illustrative examples, hinge 112 is continuous hinge 116.Continuous hinge 116 may also be referred to as a “piano hinge.” In someillustrative examples, continuous hinge 116 has length 118 equivalent tolength 120 of first edge 104. In some illustrative examples, hinge 112is gooseneck hinge 122.

Composite sandwich panel 100 comprises first composite skin 124, secondcomposite skin 126, and hollow cell core 128 between first compositeskin 124 and second composite skin 126. First composite skin 124 andsecond composite skin 126 are compressed against hollow cell core 128 toform composite sandwich panel 100. In some illustrative examples, hollowcell core 128 takes the form of honeycomb core 129. In some illustrativeexamples, hollow cell core 128 is corrugated as shown in FIG. 5 .

Composite sandwich panel 100 has first face 130 and second face 132opposite first face 130. First face 130 is part of first composite skin124. Second face 132 is part of second composite skin 126.

In some illustrative examples, second face 132 has concave surface 134within first over-crush edge region 106. Concave surface 134 may haveany desirable shape. In some illustrative examples, concave surface 134is curved. In some illustrative examples, concave surface 134 is a ramp.In some illustrative examples, concave surface 134 is a combination ofstraight and curved sections.

First edge 104 of first over-crush edge region 106 has first thickness136. First thickness 136 is less than nominal thickness 138 of compositesandwich panel 100. Nominal thickness 138 is thickness 108 of compositesandwich panel 100 after consolidation of first composite skin 124,hollow cell core 128, and second composite skin 126 to form compositesandwich panel 100. First thickness 136 is in the range of 40%-15% ofnominal thickness 138 of composite sandwich panel 100. In someillustrative examples, first thickness 136 is in the range of 30%-20% ofnominal thickness 138 of composite sandwich panel 100. In someillustrative examples, first thickness 136 has an 80% over-crush. Inthese illustrative examples, first thickness 136 is approximately 20% ofnominal thickness 138 of composite sandwich panel 100. In someillustrative examples, nominal thickness 138 may be referred to as an“uncrushed thickness.”

First edge 104 is cut 140. Portions of first composite skin 124, hollowcell core 128, and second composite skin 126 are visible at first edge104. First edge 104 has flat appearance 142 without visible core cells144.

In some illustrative examples, composite sandwich panel 100 furthercomprises second over-crush edge region 146. Second over-crush edgeregion 146 comprises second edge 148 with second thickness 150. Secondthickness 150 is less than nominal thickness 138 of composite sandwichpanel 100. Second thickness 150 is in the range of 40%-15% of nominalthickness 138 of composite sandwich panel 100. In some illustrativeexamples, second thickness 150 is in the range of 30%-20% of nominalthickness 138 of composite sandwich panel 100. In some illustrativeexamples, second thickness 150 has an 80% over-crush. In theseillustrative examples, second thickness 150 is approximately 20% ofnominal thickness 138 of composite sandwich panel 100.

Second edge 148 is cut 152. Portions of first composite skin 124, hollowcell core 128, and second composite skin 126 are visible at second edge148. Second edge 148 has flat appearance 142 without visible core cells144.

In some illustrative examples, second face 132 has concave surface 154within second over-crush edge region 146. Concave surface 154 may haveany desirable shape. In some illustrative examples, concave surface 154is curved. In some illustrative examples, concave surface 154 is a ramp.In some illustrative examples, concave surface 154 is a combination ofstraight and curved sections.

In some illustrative examples, composite sandwich panel 100 furthercomprises third over-crush edge region 156. Third over-crush edge region156 comprises third edge 158 with third thickness 160. Third thickness160 is less than nominal thickness 138 of composite sandwich panel 100.Third thickness 160 is in the range of 40%-15% of nominal thickness 138of composite sandwich panel 100. In some illustrative examples, thirdthickness 160 is in the range of 30%-20% of nominal thickness 138 ofcomposite sandwich panel 100. In some illustrative examples, thirdthickness 160 has an 80% over-crush. In these illustrative examples,third thickness 160 is approximately 20% of nominal thickness 138 ofcomposite sandwich panel 100.

Third edge 158 is cut 162. Portions of first composite skin 124, hollowcell core 128, and second composite skin 126 are visible at third edge158. Third edge 158 has flat appearance 142 without visible core cells144.

In some illustrative examples, second face 132 has concave surface 164within third over-crush edge region 156. Concave surface 164 may haveany desirable shape. In some illustrative examples, concave surface 164is curved. In some illustrative examples, concave surface 164 is a ramp.In some illustrative examples, concave surface 164 is a combination ofstraight and curved sections.

Composite sandwich panel 100 comprises fourth edge 166. Fourth edge 166has fourth thickness 168. Fourth thickness 168 is substantially the sameas nominal thickness 138. Fourth edge 166 has visible core cells 144. Insome illustrative examples, edge trim 170 is applied to fourth edge 166to cover visible core cells 144.

In some illustrative examples, portions of composite sandwich panel 100are painted. In some illustrative examples, at least one of first face130, first edge 104, second edge 148, or third edge 158 is painted. Insome illustrative examples, composite sandwich panel 100 furthercomprises decorative laminate 172. In some illustrative examples,decorative laminate 172 covers first face 130 and first edge 104. Insome illustrative examples, decorative laminate 172 covers first face130, first edge 104, second edge 148, and third edge 158.

By forming composite sandwich panel 100 in a crush core press, at leastone edge is “over-crushed” to the point that the at least one edgebehaves like solid fiberglass. In this illustrative example, each offirst edge 104, second edge 148, and third edge 158 is produced using an“over-crush” process. The “over-crush” process uses heat and pressure tocompress hollow cell core 128, first composite skin 124, and secondcomposite skin 126 into a solid substrate along each of first edge 104,second edge 148, and third edge 158 of composite sandwich panel 100.

By using this “over-crush” process on first edge 104, second edge 148,and third edge 158, durable edges are created that do not use edgetrims. By using this “over-crush” process, door 174 takes advantage ofthe benefits of a composite sandwich panel having a hollow cell core. Inparticular, a strength and a stiffness of composite sandwich panel 100is maintained. Increasing a strength and a stiffness of door 174 resultsin a more durable product.

Fourth edge 166 of composite sandwich panel 100, which is notover-crushed, allows volatile compounds to escape during the moldingprocess. An injection-molded edge trim, such as edge trim 170, can beapplied to fourth edge 166. In some illustrative examples, fourth edge166 is hidden beneath a countertop where edge trim 170 does not create adecorative concern.

To form composite sandwich panel 100, hollow cell core 128, firstcomposite skin 124, and second composite skin 126 are placed into tool176 with dies 178. When closed, dies 178 of tool 176 form interior shape180. Interior shape 180 applies “over-crush” pressure to portions ofcomposite sandwich panel 100 to form first over-crush edge region 106,second over-crush edge region 146, and third over-crush edge region 156.

After performing an “over-crush” process to form composite sandwichpanel 100, composite sandwich panel 100 is cut using numericallycontrolled machinery 182. Numerically controlled machinery 182 is usedto form cut 140 first edge 104, cut 152 second edge 148, and cut 162third edge 158.

In some illustrative examples, composite sandwich panel 100, seal 110,and hinge 112 form door assembly 184. Door assembly 184 is installedinto cabinetry to form a door, such as door 174 of cabinetry 186.

Seal 110 is configured to perform desired functions in door assembly184. Seal 110 is configured to close a gap of door assembly 184 incabinetry, such as cabinetry 186. In some illustrative examples, seal110 is formed of polymeric material 188. In some illustrative examples,seal 110 is formed of silicone 190. In some illustrative examples,polymeric material 188 is reinforced 192. Seal 110 is bonded to firstover-crush edge region 106 after using numerically controlled machinery182 used to form cut 140 first edge 104.

After bonding seal 110 to first over-crush edge region 106, hinge 112 isconnected to composite sandwich panel 100. In some illustrativeexamples, hinge 112 is also connected to cabinetry 186 in lavatory 194of aircraft 196. In some illustrative examples, hinge 112 is connectedto composite sandwich panel 100 prior to connecting hinge 112 tocabinetry 186. In some illustrative examples, hinge 112 is connected tocabinetry 186 prior to connecting hinge 112 to composite sandwich panel100.

Hinge 112 is connected to composite sandwich panel 100 using fasteners198. In some illustrative examples, prior to connecting hinge 112 tocomposite sandwich panel 100, drilling and potting steps are performedon composite sandwich panel 100. In these illustrative examples, thedrilling and potting steps position fastener receivers. In theseillustrative examples, fasteners 198 are connected to fastener receiversin composite sandwich panel 100.

As used herein, the phrase “at least one of,” when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used, and only one of each item in the list may be needed. Inother words, “at least one of” means any combination of items and numberof items may be used from the list, but not all of the items in the listare required. The item may be a particular object, a thing, or acategory.

This example also may include item A, item B, and item C, or item B anditem C. Of course, any combination of these items may be present. Inother examples, “at least one of” may be, for example, withoutlimitation, two of item A, one of item B, and ten of item C; four ofitem B and seven of item C; or other suitable combinations.

The illustration of manufacturing environment 102 in FIG. 1 is not meantto imply physical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components in additionto or in place of the ones illustrated may be used. Some components maybe unnecessary. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

Turning now to FIG. 2 , an illustration of a front view of a lavatorycabinetry with a door formed of a composite sandwich panel is depictedin accordance with an illustrative embodiment. Cabinetry 200 is aphysical implementation of cabinetry 186 of FIG. 1 .

Cabinetry 200 has door 202 and door 204. Door 202 may be a physicalimplementation of door 174 of FIG. 1 . Door 204 may be a physicalimplementation of door 174 of FIG. 1 .

In some illustrative examples, cabinetry 200 is positioned in lavatory194 of FIG. 1 . In some illustrative examples, cabinetry 200 may bepositioned beneath a countertop.

Cabinetry 200 is configured to have desirable durability. Further,cabinetry 200 is designed such that door 202 and door 204 are notobviously doors. Cabinetry 200 is designed such that passengers in anaircraft do not probe door 202 and door 204.

Turning now to FIG. 3 , an illustration of a back view of a lavatorycabinetry with a door formed of a composite sandwich panel is depictedin accordance with an illustrative embodiment. View 300 is a back viewof cabinetry 200. As depicted, door 202 is connected to hinge 302. Asdepicted, door 204 is connected to hinge 304.

Using hinge 302, door 202 opens in direction 306. Using hinge 304, door204 opens in direction 308.

Turning now to FIG. 4 , an illustration of a front isometric view of acomposite sandwich panel is depicted in accordance with an illustrativeembodiment. Composite sandwich panel 400 is a physical implementation ofcomposite sandwich panel 100 of FIG. 1 . In some illustrative examples,composite sandwich panel 400 is a component of door 202 of FIG. 2 .

As depicted, composite sandwich panel 400 has first edge 402, secondedge 404, third edge 406, and fourth edge 408. Each of first edge 402,second edge 404, and third edge 406 has a flat appearance withoutvisible core cells. First edge 402 is in first over-crush edge region410. First over-crush edge region 410 has concave surface 412.

Second edge 404 is in second over-crush edge region 414. Secondover-crush edge region 414 has concave surface 416. Third edge 406 is inthird over-crush edge region 418. Third over-crush edge region 418 hasconcave surface 420.

Turning now to FIG. 5 , an illustration of a back isometric view of acomposite sandwich panel is depicted in accordance with an illustrativeembodiment. View 500 is a back isometric view of composite sandwichpanel 400 from fourth edge 408.

As depicted, fourth edge 408 has visible core cells 502. In someillustrative examples, prior to being placed into service, an edgetreatment will be applied to fourth edge 408. In some illustrativeexamples, prior to being placed into service, an edge trim is adhered tofourth edge 408.

Turning now to FIG. 6 , an illustration of a front isometric view of acomposite sandwich panel with a seal is depicted in accordance with anillustrative embodiment. In view 600, seal 602 has been bonded to firstover-crush edge region 410. Seal 602 extends past first edge 402. Seal602 is a physical implementation of seal 110 of FIG. 1 .

Seal 602 is formed of any desirable material. In some illustrativeexamples, seal 602 is formed of a polymeric material. In someillustrative examples, seal 602 is formed of a reinforced material.

Turning now to FIG. 7 , an illustration of a front isometric view of acomposite sandwich panel with a seal and a hinge is depicted inaccordance with an illustrative embodiment. In view 700, hinge 702 hasbeen connected to composite sandwich panel 400 such that axis ofrotation 704 of hinge 702 is positioned over first over-crush edgeregion 410 of composite sandwich panel 400. As depicted, hinge 702 iscontinuous hinge 706. As depicted, hinge 702 is gooseneck hinge 708.

In some illustrative examples, composite sandwich panel 400, seal 602,and hinge 702 are referred to as door assembly 710. Composite sandwichpanel 400 has cut first edge 402, cut second edge 404, and cut thirdedge 406 each with a flat appearance without visible core cells. Asdepicted, seal 602 is bonded to composite sandwich panel 400 adjacentcut first edge 402. Hinge 702 is connected to composite sandwich panel400 adjacent cut first edge 402.

As depicted, cut first edge 402 is within first over-crush edge region410 of composite sandwich panel 400, wherein seal 602 is bonded to firstover-crush edge region 410. As depicted, hinge 702 is connected tocomposite sandwich panel 400 such that an axis of rotation of hinge 702is positioned over first over-crush edge region 410.

Turning now to FIG. 8 , an illustration of a side view of a compositesandwich panel is depicted in accordance with an illustrativeembodiment. View 800 is a side view of first over-crush edge region 410of composite sandwich panel 400.

As depicted, concave surface 412 of first over-crush edge region 410 iscurved 802. As depicted, first edge 402 is cut 804. Thickness 806 offirst edge 402 is considerably less than nominal thickness 808 ofcomposite sandwich panel 400.

Turning now to FIG. 9 , an illustration of a side view of a compositesandwich panel with a seal is depicted in accordance with anillustrative embodiment. View 900 is a side view of first over-crushedge region 410 of composite sandwich panel 400 with seal 602. Asdepicted, seal 602 extends over first edge 402. As depicted, seal 602stops within first over-crush edge region 410.

Turning now to FIG. 10 , an illustration of a side view of a compositesandwich panel with a seal and a hinge is depicted in accordance with anillustrative embodiment. View 1000 is a side view of first over-crushedge region 410 of composite sandwich panel 400 with seal 602 and hinge702. Hinge 702 has been connected to composite sandwich panel 400 suchthat axis of rotation 704 of hinge 702 is positioned over firstover-crush edge region 410 of composite sandwich panel 400. As depicted,hinge 702 is gooseneck hinge 708. As depicted, seal 602 ends prior tohinge 702.

Turning now to FIG. 11 , another illustration of a side view of acomposite sandwich panel with a seal and a hinge is depicted inaccordance with an illustrative embodiment. View 1100 is a side view offirst over-crush edge region 410 of composite sandwich panel 400 withseal 602 and hinge 702. Hinge 702 has been connected to compositesandwich panel 400 such that axis of rotation 704 of hinge 702 ispositioned over first over-crush edge region 410 of composite sandwichpanel 400. As depicted, hinge 702 is gooseneck hinge 708. As depicted, aportion of seal 602 is sandwiched between hinge 702 and compositesandwich panel 400.

Turning now to FIG. 12 , an illustration of a side view of a compositesandwich panel with a seal and a hinge installed in cabinetry and in aclosed position is depicted in accordance with an illustrativeembodiment. View 1200 is a side view of composite sandwich panel 1202.Composite sandwich panel 1202 is a physical implementation of compositesandwich panel 100 of FIG. 1 . Composite sandwich panel 1202 may becomposite sandwich panel 400 of FIGS. 4-11 . In some illustrativeexamples, composite sandwich panel 1202 is a component of one of door202 or door 204.

As depicted, composite sandwich panel 1202 has first over-crush edgeregion 1204 with first edge 1206. Seal 1208 is bonded to firstover-crush edge region 1204. Hinge 1210 is connected to compositesandwich panel 1202 such that axis of rotation 1212 is positioned overfirst over-crush edge region 1204.

Hinge 1210 is also connected to supporting structure 1214 of cabinetry1216. Door assembly 1218 including composite sandwich panel 1202, seal1208, and hinge 1210 is in closed position 1220. Connecting hinge 1210to cabinetry 1216 forms a composite door, such as door 202 or door 204of FIG. 2 . In closed position 1220, seal 1208 contacts facing 1222. Inclosed position 1220, first face 1224 is substantially flush with facing1222. Seal 1208 seals gap 1226 between composite sandwich panel 1202 andfacing 1222. Seal 1208 deters entry of water or other contaminates tointerior 1228 of cabinetry 1216.

For an acceptable appearance, consistent, tight gaps are desirablebetween panels. Gaps are desirably closed out while not sacrificing adecorative appearance. When a decorative laminate is applied tocomposite sandwich panel 1202, seal 1208 can be colored to match thedecorative laminate. Seal 1208 is configured to close out any gaps witha consistent appearance.

Turning now to FIG. 13 , an illustration of a side view of a compositesandwich panel with a seal and a hinge installed in cabinetry and in anopen position is depicted in accordance with an illustrative embodiment.View 1300 is a side view of composite sandwich panel 1202. In view 1300,door assembly 1218 is in open position 1302.

Turning now to FIG. 14 , an illustration of a flowchart of a method forforming and using a composite sandwich panel is depicted in accordancewith an illustrative embodiment. Method 1400 may be used to form doorassembly 184 of FIG. 1 or door assembly 1218 of FIG. 12 . Method 1400may be used to form any of composite sandwich panel 100 of FIG. 1 ,composite sandwich panel 400 of FIG. 2 , or composite sandwich panel1202 of FIG. 12 .

Method 1400 bonds a seal to a first over-crush edge region of acomposite sandwich panel, wherein a thickness of the composite sandwichpanel decreases within the first over-crush edge region in a directiontowards a first edge of the composite sandwich panel within the firstover-crush edge region (operation 1402). Method 1400 connects a hinge tothe first over-crush edge region of the composite sandwich panel(operation 1404). Afterwards, the method terminates.

In some illustrative examples, method 1400 also connects the hinge tocabinetry to form a composite door (operation 1406). In someillustrative examples, the cabinetry is within a lavatory of an aircraft(operation 1408).

In some illustrative examples, method 1400 applies heat and acompressive force to the composite sandwich panel to form the firstover-crush edge region (operation 1410). In some illustrative examples,method 1400 applies a decorative laminate over a first face and thefirst edge of the composite sandwich panel (operation 1412).

In some illustrative examples, the first face is opposite to a secondface having a concave surface in the first over-crush edge region(operation 1414). In some illustrative examples, method 1400 appliesheat and a compressive force to the composite sandwich panel to form asecond over-crush edge region and a third over-crush edge region(operation 1416).

In some illustrative examples, method 1400 allows volatiles to escapethrough a fourth edge of the composite sandwich panel while forming thesecond over-crush edge region and the third over-crush edge region ofthe composite sandwich panel (operation 1418). In some illustrativeexamples, method 1400 applies a decorative laminate over the first edge,a second edge within the second over-crush edge region, and a third edgewithin the third over-crush edge region (operation 1420). In someillustrative examples, method 1400 applies an edge trim to the fourthedge (operation 1422).

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatus and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent a module, a segment, a function, and/or a portionof an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added, in addition tothe illustrated blocks, in a flowchart or block diagram.

In some illustrative examples, not all blocks of method 1400 areperformed. For example, operations 1406 through 1422 are optional.

The illustrative embodiments of the present disclosure may be describedin the context of aircraft manufacturing and service method 1500 asshown in FIG. 15 and aircraft 1600 as shown in FIG. 16 . Turning firstto FIG. 15 , an illustration of an aircraft manufacturing and servicemethod is depicted in accordance with an illustrative embodiment. Duringpre-production, aircraft manufacturing and service method 1500 mayinclude specification and design 1502 of aircraft 1600 in FIG. 16 andmaterial procurement 1504.

During production, component and subassembly manufacturing 1506 andsystem integration 1508 of aircraft 1600 takes place. Thereafter,aircraft 1600 may go through certification and delivery 1510 in order tobe placed in service 1512. While in service 1512 by a customer, aircraft1600 is scheduled for routine maintenance and service 1514, which mayinclude modification, reconfiguration, refurbishment, and othermaintenance or service.

Each of the processes of aircraft manufacturing and service method 1500may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers or major-systemsubcontractors; a third party may include, without limitation, anynumber of vendors, subcontractors, or suppliers; and an operator may bean airline, a leasing company, a military entity, a serviceorganization, and so on.

With reference now to FIG. 16 , an illustration of an aircraft isdepicted in which an illustrative embodiment may be implemented. In thisexample, aircraft 1600 is produced by aircraft manufacturing and servicemethod 1500 in FIG. 15 and may include airframe 1602 with a plurality ofsystems 1604 and interior 1606. Examples of systems 1604 include one ormore of propulsion system 1608, electrical system 1610, hydraulic system1612, and environmental system 1614. Any number of other systems may beincluded. Although an aerospace example is shown, different illustrativeembodiments may be applied to other industries, such as the automotiveindustry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 1500. Oneor more illustrative embodiments may be used during component andsubassembly manufacturing 1506, system integration 1508, or maintenanceand service 1514 of FIG. 15 . For example, door assembly 184 includingcomposite sandwich panel 100 may assembled during component andsubassembly manufacturing 1506. As another example, door assembly 184including composite sandwich panel 100 may be a replacement part duringmaintenance and service 1514 of FIG. 15 .

Apparatuses and methods embodied herein may be employed in manufacturingat least one component of aircraft 1600. For example, composite sandwichpanel 100 of FIG. 1 may be manufactured to form a portion of interior1606.

The illustrative examples present methods and apparatuses to usecomposite sandwich panels, including fiberglass panels, in lieu ofstandard thermoplastic doors. The illustrative examples present crushedcore fiberglass door panels to be used in cabinetry. In someillustrative examples, the cabinetry may be present in the lavatory ofan aircraft.

As presented, the over-crushed door panels can be painted. It is alsopossible to apply decorative laminates to the decorative surfaces of theover-crushed door panels. The decorative laminate can be wrapped aroundthe three crushed edges for a seamless appearance.

The use of these over-crushed door panels may increase durability andaesthetics. It is desirable to maintain consistent, tight gaps betweenpanels. It is also desirable to close out gaps while not sacrificing adecorative appearance.

By bonding a flap seal to the over-crushed edges of the panel, the gapsare closed out. The seal can be colored to match the decorative laminateapplied to the panel, and the seal closes out any gaps with a consistentappearance.

In addition to the flap seal, a new type of continuous (piano) hinge hasbeen created that allows the hinge side of the door to retract into thecompartment, which allows the flap seals to avoid interference. Thehinge design allows the seal to stay behind the door panel, and closestightly when the door is closed. The use of a continuous hinge increasesdurability and reduces sagging. The hinge design maintains straight,tight gaps between door panels.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method comprising: bonding a seal to a firstover-crush edge region of a composite sandwich panel, wherein athickness of the composite sandwich panel decreases within the firstover-crush edge region in a direction towards a first edge of thecomposite sandwich panel within the first over-crush edge region;connecting a hinge to the first over-crush edge region of the compositesandwich panel; applying heat and a compressive force to the compositesandwich panel to form the first over-crush edge region; applying a heatand a compressive force to the composite sandwich panel and forming asecond over-crush edge region and a third over-crush edge region; andallowing volatiles to escape through a fourth edge of the compositesandwich panel while forming the second over-crush edge region and thethird over-crush edge region of the composite sandwich panel.
 2. Themethod of claim 1 further comprising: applying a decorative laminateover the first edge, a second edge within the second over-crush edgeregion, and a third edge within the third over-crush edge region; andapplying an edge trim to the fourth edge.
 3. The method of claim 2further comprising: connecting the hinge to cabinetry to form acomposite door.
 4. The method of claim 3, wherein the cabinetry iswithin a lavatory of an aircraft.
 5. The method of claim 1 furthercomprising: connecting the hinge to cabinetry to form a composite door.6. The method of claim 5, wherein the cabinetry is within a lavatory ofan aircraft.
 7. A method comprising: bonding a seal to a firstover-crush edge region of a composite sandwich panel, wherein athickness of the composite sandwich panel decreases within the firstover-crush edge region in a direction towards a first edge of thecomposite sandwich panel within the first over-crush edge region;connecting a hinge to the first over-crush edge region of the compositesandwich panel; applying heat and a compressive force to the compositesandwich panel to form the first over-crush edge region; allowingvolatiles to escape through a fourth edge of the composite sandwichpanel while forming a second over-crush edge region and a thirdover-crush edge region of the composite sandwich panel; and applying adecorative laminate over a first face and the first edge of thecomposite sandwich panel.
 8. The method of claim 7, wherein the firstface is opposite to a second face having a concave surface in the firstover-crush edge region.
 9. The method of claim 8 further comprising:connecting the hinge to cabinetry to form a composite door.
 10. Themethod of claim 9, wherein the cabinetry is within a lavatory of anaircraft.
 11. The method of claim 7 further comprising: connecting thehinge to cabinetry to form a composite door.
 12. The method of claim 11,wherein the cabinetry is within a lavatory of an aircraft.
 13. A methodfor rotating a composite panel within an aircraft, the methodcomprising: overlaying a first composite skin with a hollow cell coreand a second composite skin; forming the composite panel by applying anover-crush pressure into the second composite skin and the hollow cellcore from a first edge of the second composite skin into a border of afirst over-crush edge region of the composite panel along an entirelength of the first edge of the second composite skin while sandwichingthe hollow cell core between the first composite skin and the secondcomposite skin and reducing a thickness of a first edge of the firstover-crush edge region to a lesser dimension than a thickness at theborder of the first over-crush edge region of the composite panelcomprising the hollow cell core sandwiched between the first compositeskin and the second composite skin; bonding a seal to the secondcomposite skin along the entire length of the first over-crush edgeregion and extending off the first over-crush edge region beyond thefirst edge of the first over-crush edge region; connecting a hinge to astructure in the aircraft and along a full length of the secondcomposite skin such that an axis of rotation of the hinge is over thesecond composite skin in the first over-crush edge region; and applyingthe over-crush pressure into the second composite skin and the hollowcell core from a second edge of the second composite skin into a borderof a second over-crush edge region along an entire length of the secondedge of the second composite skin while sandwiching the hollow cell corebetween the first composite skin and the second composite skin andreducing a thickness of the second edge to a lesser dimension than athickness at the border of the second over-crush edge region of thecomposite panel comprising the hollow cell core sandwiched between thefirst composite skin and the second composite skin.
 14. The method ofclaim 13, further comprising the over-crush pressure producing a solidsubstrate along the first edge of the first over-crush edge region. 15.The method of claim 13, further comprising the over-crush pressureproducing a solid substrate comprising solid fiberglass along the firstedge of the first over-crush edge region.
 16. The method of claim 13,further comprising applying heat while applying the over-crush pressure.17. The method of claim 13, further comprising the thickness of thefirst edge of the first over-crush edge region comprising 20% of thethickness at the border of the first over-crush edge region.
 18. Themethod of claim 13, further comprising the thickness of the first edgeof the first over-crush edge region comprising a range of 15-40% of thethickness at the border of the first over-crush edge region.
 19. Amethod for rotating a composite panel within an aircraft, the methodcomprising: overlaying a first composite skin with a hollow cell coreand a second composite skin; forming the composite panel by applying anover-crush pressure into the second composite skin and the hollow cellcore from a first edge of the second composite skin into a border of afirst over-crush edge region of the composite panel along an entirelength of the first edge of the second composite skin while sandwichingthe hollow cell core between the first composite skin and the secondcomposite skin and reducing a thickness of a first edge of the firstover-crush edge region to a lesser dimension than a thickness at theborder of the first over-crush edge region of the composite panelcomprising the hollow cell core sandwiched between the first compositeskin and the second composite skin; bonding a seal to the secondcomposite skin along the entire length of the first over-crush edgeregion and extending off the first over-crush edge region beyond thefirst edge of the first over-crush edge region; connecting a hinge to astructure in the aircraft and along a full length of the secondcomposite skin such that an axis of rotation of the hinge is over thesecond composite skin in the first over-crush edge region; and applyingthe over-crush pressure into the second composite skin and the hollowcell core from a third edge of the second composite skin into a borderof a third over-crush edge region along an entire length of the thirdedge of the second composite skin while sandwiching the hollow cell corebetween the first composite skin and the second composite skin andreducing a thickness of the third edge to a lesser dimension than athickness at the border of the third over-crush edge region of thecomposite panel comprising the hollow cell core sandwiched between thefirst composite skin and the second composite skin.
 20. The method ofclaim 19, further comprising the over-crush pressure producing a solidsubstrate along the first edge of the first over-crush edge region. 21.The method of claim 19, further comprising the over-crush pressureproducing a solid substrate comprising solid fiberglass along the firstedge of the first over-crush edge region.
 22. The method of claim 19,further comprising applying heat while applying the over-crush pressure.23. The method of claim 19, further comprising the thickness of thefirst edge of the first over-crush edge region comprising 20% of thethickness at the border of the first over-crush edge region.
 24. Themethod of claim 19, further comprising the thickness of the first edgeof the first over-crush edge region comprising a range of 15-40% of thethickness at the border of the first over-crush edge region.